Method for the production of a plastic pallet

ABSTRACT

The invention relates to a method for the production of an assembled plastic pallet, consisting in producing 13 small identical plastic parts and assembling said parts, by means of interlocking, in order to produce the end plastic pallet, in various sizes, said pallet being intended for a wide range of uses associated with the transport and unloading of goods using a forklift truck.

BACKGROUND TO THE INVENTION

The pallet is the platform on which loads or materials are placed toenable a forklift truck to lift and transport them. Pallets come indifferent sizes so that they can suit different uses, but the mostimportant common sizes are:

1.1 m×1.3 m,1 m×1.2 m,1 m×1 m.

Wood is considered the most common material used for the production ofpallets worldwide, followed by plastic, despite the fact that plastic issuperior to wood in terms of durability and its ability to be cleanedand recycled. However, up until now, it has been unable to replace wood,due to the high costs of both production and of the raw material.

The reason for the high production cost of the plastic pallet is that itis a large piece, which requires a large injection machine with acapacity of around 3,000 tonnes in order to produce it. It would alsorequire a large mould. Therefore, the speed of production would berelatively slow and the cost of investment very high. Moreover, theproduction of large pieces by the injection method is consideredcomplicated in terms of guaranteeing the strength and cohesion of thepiece, which comes at the expense of increasing the weight of the palletso that it is durable. There is a persistent desire amongst manycompanies worldwide to replace wood with plastic, however, the largedifference in costs remains an obstacle to this change.

This invention represents a major breakthrough that will help in theresolution of this problem, thereby increasing the offering of plasticpallets; and reducing their costs so that they can compete with woodenpallets. The traditional method currently used to produce plasticpallets cannot increase the offering or reduce the costs, due to thehigh investment costs in large machinery, as well as slow production.However, this invention will enable small and medium sized factories toproduce plastic pallets with the machinery already available to them andto purchase moulds at lower costs.

GENERAL DESCRIPTION OF THE INVENTION

The main aim of this invention is to devise a method for producing theplastic pallet at a reduced cost from that of the plastic pallet that isproduced as a single piece, which shall be achieved by the speed ofproduction and its light weight.

The invention depends on the gathering and assembly of small identicalpieces in order to produce the complete large pallet. The production ofsmall pieces by the method of injection is characterised by its abilityto strengthen the pieces ability to bear a larger load while weighingless, by utilising the technique of repeated reinforcement. Moreover,the production of the small pieces will be quicker and require the useof a medium sized injection machine (500-600 tonnes) in comparison tothe 3,000 tonnes required to produce the pallet as a single piece. Thisinvention has been designed as 5 different small pieces, which are puttogether to form the assembled plastic pallet, whereby every end palletcontains 13 pieces. The method of assembly merely requires interlockingand does not require any external tools.

Using this invention, it is possible to produce all the sizes of palletsrequired by changing the measurements of the small pieces. With regardsto weight, we have used this invention to produce an assembled plasticpallet with the measurements 1.1 m×1.3 m, the weight of which does notexceed 12.5 kg; and which can bear a moving load of up to 1,400 kg and astationary load of up to 4,000 kg, in the knowledge that the lightestplastic pallet available on the market now, which can bear the sameloads, weighs 17 kg.

SHORT DESCRIPTION OF THE DRAWINGS

The specifications, features and method of use of this invention willbecome clearer through the description which we shall provide throughthe attached figures. These clarify the shapes of the small pieces andthe assembly steps required in order to produce the assembled plasticpallet:

FIG. 1:—Depicts the small pieces that form the assembled plastic pallet,which are five pieces as follows:

-   -   Piece 1: This forms the upper part of the pallet and has been        designed symmetrically. It has four legs (7) of equal        dimensions, which have negative slots to receive the positive        locks from the lower piece (2).    -   Piece 2: This forms the lower part of the pallet. Care has been        taken in its design to ensure strength, durability and the        symmetry of its dimensions, in order to give the pallet        stability when being moved on conveyor belts and during the        loading process. The piece has four slots (6), in which positive        locks have been placed in order to fit into the legs with        negative slots in the upper piece. Thus, the process of        interlocking is completed firmly.    -   Piece 3: This is the connecting link in the centre of the        pallet. It was designed in a rectangular shape and at a height        that exactly equals the height of the slots (6) in the lower        piece (2) and with an appropriate thickness, which provides it        with the strength required to ensure stability, as it is the        main connecting link between the pieces that form the assembled        pallet.    -   Piece 4: It is the first side connecting link. It was designed        in a rectangular shape and at the same height and thickness of        the connecting link (3), but differs in its dimensions, as it        meets piece (3) to complete the fastening of the sides.    -   Piece 5: It is the second side connecting link. It was designed        in a rectangular shape and at the same height and thickness of        the connecting link (3), but differs in its dimensions, as it        meets piece (3) to complete the fastening of the sides.

FIG. 2:—Depicts the first step of the assembly method.

FIG. 3:—Depicts the second step of the assembly method.

FIG. 4:—Depicts the third step of the assembly method.

FIG. 5:—Depicts the fourth step of the assembly method and the finalform of the end pallet.

DETAILED DESCRIPTION

The attached figures depict the shapes and number of small pieces thatform the assembled plastic pallet. There are five pieces, as illustratedby FIG. 1, which are repeatedly assembled to form a total of 13 piecesfor every pallet, as follows:

First Step: Four pieces of piece (2) are placed side by side as shown inFIG. 2. This is aided by the symmetrical design of these pieces and thepresence of raised equal sides further aids their easy and quickassembly.

Second Step: The side connecting links (4 and 5) are put in place,whereby every raised slot (6) is linked together by the connecting links(4 and 5). In the centre, four slots (6) are tied together by oneconnecting link. This process is completed with ease and without the useof any external tools. It is aided by the stability and symmetry of thedimensions of the lower piece (2). FIG. 3 illustrates this step.

Third Step: Four of the upper pieces (1) are placed over piece 2,whereby every piece is put in place by inserting the legs (7) on piece(1) in the raised slots (6) that correspond to them in piece (2). FIG. 4illustrates this step.

Fourth Step: Piece (1) is forcefully interlocked into piece (2) by usingthe hands to press down until a locking sound is heard, whereby thenegative slots in (7) will meet the positive locks in (6), thereby,concluding the Positive Locking process. The pieces cannot then beseparated except by being broken. At the end of the process, we willhave an assembled pallet comprising of a single cohesive piece, as theconnecting links have become part of the body of the pallet; and thepositive locks hold the upper and lower pieces together. Diagram number5 illustrates this step.

1. Pallet formed of 13 small pieces, which are assembled together toform the structure of the pallet, wherein the base is formed from fourpieces (2) identical as to shape and dimensions, with raised slots (6);all of which are tied together by side connecting links (4 and 5),wherein every raised slot is linked together by the connecting links (4and 5); in the centre, four slots are tied together by one connectinglink (3); thus, the base of the pallet is created; thereafter, four ofthe upper pieces (1), which are identical in shape and dimensions andwhich have side legs (7), are put into place by inserting the legs (7)in the raised slots (6) in the base and pressed down until theinterlocking process is complete.
 2. Pallet according to claim (1),wherein most of the pieces will be produced from plastic materials orsimilar materials.
 3. Pallet according to claim (1), wherein the legsare inserted into each corresponding slot in the base, the piece islocked and cannot be separated again.
 4. Pallet according to claim (1),wherein the pallet can be made in different measurements by altering thepieces used, whether the upper, lower or connecting links.